U.S. patent number 8,015,657 [Application Number 11/870,939] was granted by the patent office on 2011-09-13 for vacuum electronic power tool sense.
This patent grant is currently assigned to Black & Decker Inc.. Invention is credited to David R. Beers, Kathy E. DiPasquale, Spencer G. Maid.
United States Patent |
8,015,657 |
Beers , et al. |
September 13, 2011 |
Vacuum electronic power tool sense
Abstract
A vacuum electronic power tool sense system senses the operation
of a power tool that is plugged into an onboard power outlet and
the vacuum source is automatically operated to facilitate user
clean-up of debris generated by use of the power tool. A delay
period can be utilized to maintain the vacuum source is an on state
for a predetermined period of time after the power tool is turned
off.
Inventors: |
Beers; David R. (Dallastown,
PA), DiPasquale; Kathy E. (Baltimore, MD), Maid; Spencer
G. (Hartland, WI) |
Assignee: |
Black & Decker Inc.
(Newark, DE)
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Family
ID: |
39433896 |
Appl.
No.: |
11/870,939 |
Filed: |
October 11, 2007 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20080189899 A1 |
Aug 14, 2008 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60900351 |
Feb 9, 2007 |
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Current U.S.
Class: |
15/319;
15/339 |
Current CPC
Class: |
A47L
9/2842 (20130101); A47L 9/2805 (20130101); A47L
9/2889 (20130101); A47L 9/20 (20130101); A47L
9/2857 (20130101) |
Current International
Class: |
A47L
9/28 (20060101) |
Field of
Search: |
;15/319,339 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
Talema AC1030, 30 Amp Current Transformer;
http://www.talema-nuvotem.com; CT's\AC1030 05-00 (1 page). cited by
other.
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Primary Examiner: Redding; David
Attorney, Agent or Firm: Harness, Dickey & Pierce,
P.L.C.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application
No. 60/900,351, filed on Feb. 9, 2007, the disclosure of which is
incorporated herein by reference.
Claims
What is claimed is:
1. A vacuum comprising: a housing; a vacuum source disposed in said
housing; a power outlet disposed on said housing; a power tool
sensing system for sensing operation of a power tool plugged into
said power outlet; and a controller for operating said vacuum
source in response to a sensed operation of said power tool,
wherein said power tool sensing system senses a voltage applied to
the power tool and said controller operates said vacuum source in
response to voltage dips and turns off said vacuum source in
response to voltage spikes.
2. The vacuum according to claim 1, wherein said power tool sensing
system includes a current transformer for sensing current passing
through a wire carrying current to said power tool.
3. The vacuum according to claim 1, wherein said power tool sensing
system includes a coil component for detecting current through a
circuit component delivering current to said power tool.
4. The vacuum according to claim 1, wherein said controller
continues operation of said vacuum source for a predetermined
period of time after said operation of said power tool is
stopped.
5. A vacuum comprising: a housing; a vacuum source disposed in said
housing; a power outlet disposed on said housing; a power tool
sensing system for sensing operation of a power tool plugged into
said power outlet; and a controller for operating said vacuum
source in response to a sensed operation of said power tool;
wherein said power tool sensing system includes a current
transformer for sensing current passing through a wire carrying
current to said power tool, said power tool sensing circuit senses
a voltage applied to the power tool and said controller operates
said vacuum source in response to voltage dips and turns off said
vacuum source in response to voltage spikes.
6. The vacuum according to claim 5, wherein said controller
continues operation of said vacuum source for a predetermined
period of time after said operation of said power tool is stopped.
Description
FIELD
The present disclosure relates to vacuum electronics, and more
particularly to an electronic power tool sense system for a
vacuum.
BACKGROUND
The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
Conventional industrial shop vacuums are employed for both wet and
dry usage. However, the electronics for conventional industrial
shop vacuums can be primitive in design.
Conventional vacuums may include a container and a cover that
closes the container. The cover may support a vacuum motor with a
power cord. The power cord may include a power plug that may be
connected to a power source. When powered up, the vacuum motor may
rotate a suction fan, thereby drawing air from the container. A
flexible hose may be mounted on an inlet to the vacuum for drawing
debris (including solids, liquids, and gases) into the
container.
Conventional vacuums may also include an onboard power outlet that
may be electrically connected to the power cord of the vacuum. The
onboard power outlet may receive a power plug of a power tool.
Accordingly, a user may plug the power plug of the vacuum motor
into a power outlet in a wall (or some other power source), and
plug the power plug of the power tool into the onboard power outlet
of the vacuum. In this way, the vacuum motor and the power tool may
be driven with only a single power cord (i.e., the power cord of
the vacuum) being physically connected to a power source.
While the conventional onboard power outlets are generally thought
to provide acceptable performance, they are not without
shortcomings. For example, the power plug of the power tool may be
inadvertently unplugged from the onboard power outlet of the
vacuum.
SUMMARY
The present disclosure provides a vacuum electronic power tool
sense system for sensing the operation of a power tool that is
plugged into a power outlet disposed on the housing. The detection
of operation of a power tool plugged into the power outlet disposed
on the housing causes the controller to also operate a vacuum
source of the vacuum to provide simultaneous operation of the power
tool and vacuum in order to facilitate user clean-up of messes
generated by use of the power tool. If the power tool is turned
off, the vacuum source can be further operated for a predetermined
delay period to allow the vacuum to clean up additional debris
created by operation of the power tool.
According to an example, non-limiting embodiment, a vacuum may also
include a housing supporting the power outlet. A door may be
mounted for movement on the housing between an opened position and
a closed position in which the door is superposed above the power
outlet. The door may include a notch to receive a power cord of a
power tool and may prevent the plug of the power cord from being
inadvertently pulled out of the power outlet.
Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only
and are not intended to limit the scope of the present disclosure
in any way.
FIG. 1 is a perspective view of an example industrial shop vacuum
according to the principles of the present disclosure;
FIG. 2 is a schematic diagram of an example industrial shop vacuum
according to the principles of the present disclosure;
FIG. 3 is a schematic circuit diagram for the electronic controls
according to the principles of the present disclosure;
FIG. 4 is a perspective view of an alternative vacuum according to
the principles of the present disclosure;
FIG. 5 is a perspective view of an outlet cover according to the
principles of the present disclosure;
FIG. 6 is a perspective view of the outlet cover of FIG. 5 with a
power tool plugged therein;
FIG. 7 is a perspective view of a further embodiment of the outlet
cover;
FIG. 8 is a plan view of a still further embodiment of the outlet
cover;
FIG. 9 is a perspective view of a further embodiment of the outlet
cover;
FIG. 10 is a perspective view of the outlet cover of FIG. 9 with a
plug inserted in the outlet; and
FIG. 11 is a perspective view of a further embodiment of the outlet
cover.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not
intended to limit the present disclosure, application, or uses. It
should be understood that throughout the drawings, corresponding
reference numerals indicate like or corresponding parts and
features.
With reference to FIGS. 1 and 2, an example vacuum 10, according to
the principles of the present disclosure, will now be described.
The vacuum 10 may include a canister 12 and a vacuum head 14 that
closes the canister 12. The vacuum head may support a drive motor
16. The drive motor 16 may support a suction fan 18, which may be
provided in a fan chamber 20 of the vacuum head 14. The fan chamber
20 may be in fluid communication with an exhaust port 22 and an
intake port 24. The intake port 24 may be covered by a filter
assembly 26 situated in a filter housing 28 of a vacuum head
14.
A motor 16, when powered up, may rotate the suction fan 18 to draw
air into the suction inlet opening 30 and through the canister 12,
through the filter assembly 26, through the intake port 24 and into
the fan chamber 20. The suction fan 18 may push the air in the fan
chamber 20 through the exhaust port 22 and out of the vacuum 10. A
hose 32 can be attached to the inlet opening 30.
The canister 12 can be supported by wheels 34. The wheels 34 can
include caster wheels, or the wheels can alternatively be supported
by an axle.
A filter cleaning device 34 is provided including a filter cleaning
motor 36 drivingly connected to a filter cleaning mechanism 38. The
filter cleaning mechanism 38 can take many forms, and can include
an eccentrically driven arm 40 having fingers 42 engaging the
filter 26. The filter cleaning device 34 can be driven to traverse
across the filter 26 to cause debris that is stuck to the filter to
be loosened up and fall into the canister 12. The arm 40 is
connected to an eccentric drive member 44 which is connected to
motor 36 and, when rotated, causes the arm 40 and fingers 42 to
traverse across the surface of the filter 26.
With reference to FIG. 3, a schematic diagram of the electronics 50
utilized to operate the vacuum 10 will now be described. The
electronics 50 generally include a power cord 52 extending from the
vacuum and adapted for connection with an AC power source 54. In
particular, the power cord 52 can include a plug 56 (FIG. 2) having
a two-prong or three-prong connection as is known in the art, as is
shown in FIG. 2. The power cord 52 is connected to a power source
circuit 60. An electrical isolation circuit 62 is provided in
communication with the power source circuit 60 for providing a low
voltage output VCC, as will be described in greater detail herein.
A microcontroller 64 is provided in communication with the
electrical isolation circuit 62 for receiving a low voltage supply
VCC therefrom. The microcontroller 64 provides control signals to a
filter cleaning circuit 66 and a vacuum circuit 68.
A power tool sense circuit 70 is provided in communication with the
microcontroller 64 for providing a signal to the microcontroller 64
regarding operation of a power tool that is plugged into an outlet
72 that can be disposed on the power tool 10. The outlet 72 can be
connected to the power cord 52 as indicated by nodes L, N. A water
sense circuit 74 is provided in communication with the
microcontroller 64 for providing a signal ("water") to the
microcontroller 64 that the water level in the canister 12 has
reached a predetermined level for deactivating the vacuum source in
order to prevent water from being drawn into the vacuum filter
26.
A multi position switch such as four position rotary switch 75 can
be utilized for providing different activation states of a first
micro-switch S1 and a second micro-switch S2 for controlling
operation of the vacuum motor 16. The switches S1 and S2 are
connected to connectors A, B and A, C, respectively, wherein
connectors B and C are connected to ratio circuits 76, 78,
respectively. Connector A provides an input signal to the
microcontroller 64 indicative of the activation state of
micro-switch S1 and micro-switch S2 in order to provide four modes
of operation utilizing the two micro-switches S1 and S2 while
providing just a single input into the microcontroller 64. Table 1
provides a list of the mode selection possibilities of the four
position user switch 75 with micro-switches S1 and S2 in the
different activation states.
TABLE-US-00001 TABLE 1 Microcontroller Input VCC User Switch
Position S1 S2 Ratio 1 0 0 0 * VCC 2 0 1 (1/3) * VCC 3 1 0 (4/5) *
VCC 4 1 1 (5/8) * VCC
With each of the four possible activation states of micro-switches
S1 and S2, the ratio circuit 76, 78 provide different ratio input
signals as a function of the low voltage supply VCC. In particular,
by way of example as shown in Table 1, when both switch S1 and
switch S2 are open, a zero ratio VCC signal is received by the
microcontroller 64. When switch S1 is open and switch S2 is closed,
a 1/3 ratio VCC signal is provided. When the switch S1 is closed
and switch S2 is open, a 4/5 VCC ratio signal is provided, and when
both switches S1 and S2 are closed, a 5/8 VCC ratio signal is
provided to the microcontroller 64. The ratios are determined by
the resistance levels of resistors R17-R20 provided in the ratio
circuits 76, 78. Ratios, number of switches, and number of
resistors can vary for inputs other than 4. With these four input
signals provided at a single microcontroller input, four user
selectable modes are provided, thereby simplifying the
microcontroller input and reducing the cost of the
microcontroller.
The four user selectable modes can include position (1) vacuum off,
power outlet is off, auto filter clean is off and filter clean push
button is off; position (2) vacuum on, power outlet is off, auto
filter clean is off and filter clean push button is on; position
(3) vacuum on, power outlet off, auto filter clean is on and filter
clean push button is on; and position (4) (auto mode) vacuum is
controlled by outlet, auto filter clean is on and filter clean push
button is on. These operation modes are exemplary and different
modes can be enabled and disabled by the microcontroller 64.
Further, more or fewer switch positions can also be employed as
well as more micro-switches and ratio circuits can also be utilized
that are activated by the user switch for providing even further
distinct operation modes.
A filter clean switch 80 is also provided for providing a signal to
the microcontroller 64 for operating the filter cleaning device via
activation of the filter cleaning circuit 66. The filter cleaning
circuit 66 includes an opto-coupler 82 which can be activated by a
low voltage signal from the microcontroller 64. The opto-coupler 82
provides an activation signal to a triac 84. When the gate of the
triac 84 is held active, the triac 84 conducts electricity to the
filter cleaning motor 36 for activating the filter cleaning device
34. The opto-coupler 82 requires only a low power input for holding
the triac 84 active. Additionally, the triac may be held
continuously active for a time period then turned inactive, or
pulsed active/inactive for a timer period, or the triac may be
replaced by an SCR and driven with DC in a similar manner just
described.
The auto filter clean mode will turn off the vacuum for a brief
period while the filter cleaning device 34 moves across the filter
pleats. This can occur at predetermined intervals while the vacuum
is operated continuously and every time the vacuum is turned off.
The filter clean push button mode, when activated by user switch 75
and be pressing the push button 80, will cause the vacuum to turn
off for a brief period while the filter cleaning device 34 is
operated to move across the filter pleats.
The microcontroller 64 can also provide a control signal to the
vacuum circuit 68. The vacuum circuit 68 is provided with an
opto-coupler 86 which receives a low voltage signal from the
micro-controller 64. The opto-coupler 86 can provide an activation
voltage to a triac 88 which is held active by the voltage supplied
by the opto-coupler 86 to provide electricity to the vacuum motor
16. The opto-coupler 86 requires only a low power input for holding
the triac 88 active.
The power tool sense circuit 70 is provided with a current
transformer 90 that senses current passing through an electrical
connection to the power outlet 72 that supplies power to a power
tool that can be plugged into the power outlet 72. The current
transformer 90 provides a signal to the microcontroller 64
indicative to the activation state of a power tool plugged into the
outlet 72. In response to the power tool sense circuit 70, the
microcontroller 64 can automatically activate the vacuum motor 16
for driving the vacuum source. Thus, when a power tool is plugged
into the outlet 72 and is activated by a user, the vacuum motor 16
can be activated to assist in vacuuming debris that is created by
the use of the power tool. The microcontroller 64 can delay
deactivation of the vacuum motor 16 after the power tool is
deactivated, to allow for the vacuum 10 to collect debris for a
predetermined period of time after the power tool is
deactivated.
The water sense circuit 74 includes a pair of water sense probes 96
disposed within the canister 12 of the vacuum 10. Probes 96 can be
connected to vacuum head 14 and can be suspended within the
canister 12 below the level of the filter 26. A buffer device 98
buffers the high impedance water sense input. The microcontroller
on its own is unreliable in measuring the high impedance water
sense input. The output of the buffer device or amplifier 98 goes
to an analog input to the microcontroller 64. The microcontroller
software determines the analog level to detect water sense. The
water sense probes 96 can be brass probes mounted in the vacuum's
canister 12. Water contacting between the probes will be detected
by the water sense circuit 74 as a lower impedance.
The electrical isolation circuit 62 is provided to eliminate shock
hazard. Three components provide isolation including the power
supply transformer 100 as well as the current transformer 90 and
the opto-couplers 82, 86. The power supply transformer 100 provides
a reduced voltage output from the power source 54. By way of
example, a five volt reduced power supply VCC can be provided by
the electrical isolation circuit 62 from the AC line voltage source
54. The circuit 60 previous to the transformer is the control
circuit for the switching supply. The transformer provides
isolation and is part of the switching supply. The five volt
regulator takes the isolated control circuit output and reduces it
to +5V regulated. The low voltage power supply VCC is utilized by
the microcontroller 64 for providing signals to the opto-couplers
82, 86 of the filter cleaning circuit 66 and vacuum circuit 68 as
well as supplying power to the water sense circuit 74. Furthermore,
the ratio switch circuits 76, 78 are supplied with the low voltage
VCC power supply.
With reference to FIG. 4, an example vacuum 200 may include a
canister 12 and a head 14' that closes the canister 12. The head
14' may support a vacuum motor (not shown) with a power cord 52.
The power cord 52 may include a power plug 56 that may be connected
to a power source. When powered up, the vacuum motor may rotate a
suction fan (not shown), thereby drawing air from the canister 12.
A flexible hose 32 may be mounted on an inlet 30 to the vacuum for
drawing debris (including solids, liquids, and gases) into the
canister 12.
The vacuum 200 may also include an onboard power outlet 72 that may
be electrically connected to the power cord 52 of the vacuum 200.
The onboard power outlet 72 may receive a power plug of a power
tool. Accordingly, a user may plug the power plug 56 of the vacuum
motor into a power outlet in a wall (or some other power source),
and plug the power plug of the power tool into the onboard power
outlet 72 of the vacuum 200. In this way, the vacuum motor and the
power tool may be driven with only a single power cord (i.e., the
power cord 52 of the vacuum 200) being physically connected to a
power source 54.
In this example embodiment, the onboard power outlet 72 may be
provided on the head 14'. In alternative embodiments, the onboard
power outlet 72 may be provided on the canister 12 (or at some
other location on the vacuum 200). In this example embodiment, the
vacuum 200 may include two onboard power outlets 72. Alternative
embodiments may implement more or less than two onboard power
outlets 72.
Turning to FIG. 5, the onboard power outlet 72 may be mounted in a
recess 202 of the head 14'. Electrical contacts 204 of the onboard
power outlet 72 may be mounted on the bottom of the recess 202. A
door 206 may be mounted on the head 14' for pivot action (in the
direction of arrow 208) between an opened position (as shown) and a
closed position in which the door 206 may cover the recess 202. The
door 206 may pivot about an axis A. In this embodiment, the outlet
cover or door 206 pivots in a plane parallel with a surface of the
housing that surrounds the power outlet 204. By way of example
only, a mounting pin (not shown) may be fixed to the door 206 and
can be snap fitted into (and rotatable relative to) the head
14'.
The door 206 may include a notch 210. In this example embodiment,
the notch 210 may have a "U" shape. It will be readily apparent
that notches having numerous and varied shapes (other than a "U"
shape) may be suitably implemented. By way of example only, the
notch may have a curved shape, a tapered shape or a squared "U"
shape. The notch 210 may be of sufficient size to accommodate a
power cord of a power tool, but of insufficient size to allow
passage of a power plug of the power tool. Example functionality of
the door 206 will be appreciated with reference to FIG. 6, which
schematically illustrates a power tool 212 having a power cord 214
and power plug 216.
With the door 206 in the opened position (as shown in FIG. 6), an
operator may insert the power plug 216 of the power tool 212 into
the recess 202 so that the power plug 210 becomes electrically
connected to the contacts 204 of the onboard power outlet 72. The
operator may then pivot the door 206 (clockwise in FIG. 6) to the
closed position. During this pivot movement, the power cord 214 may
enter into the notch 210. In this way, the door 206 may retain the
power plug 216 of the power tool 212 in the recess 202, and resist
forces tending to pull the power plug 206 out of the onboard power
outlet 72. The operator may pivot the door 206 (counter clockwise
in FIG. 6) to the opened position to remove the power plug 216 from
the onboard power outlet 72.
EXAMPLE MODIFICATIONS
The embodiment depicted in FIG. 7 is similar to the embodiment
depicted in FIGS. 5 and 6, with the addition of a latch feature
that may provisionally secure the door 205 in the closed position.
As shown, a tab 220 may extend from the door 206, and a latch 222
may extend from the head 14'. When the door 206 is moved from the
opened position (as shown in FIG. 7) to the closed position, the
tab 220 may be positioned below the latch 222. In this condition,
an upward facing surface of the tab 220 may contact a lower facing
surface of the latch 222. The friction between the two contacting
surfaces may provisionally secure the door 206 in the closed
position.
In the disclosed embodiment, the notch 210 may be superposed above
the recess 202 when the door 206 is in the closed position. Thus,
the door 206 may not completely cover the recess 202. In
alternative embodiments, a door may be implemented to completely
cover the recess.
With reference to the example onboard power outlet 230 depicted in
FIG. 8, the door 232 may be mounted on the cover for pivot action
(arrow 234) about an axis A. The door 232 may be shaped to include
a covering portion 236 and an extended portion 238 in which the
notch 240 may be provided. As shown, the door 232 may be located at
an intermediate position (between an opened position and a closed
position), so that the power cord 214 of the power tool enters into
the notch 240 and the door 232 retains the power plug 216 of the
power tool 212 in the recess 242. The operator may pivot the door
232 (counter clockwise in FIG. 8) to the opened position to remove
the power plug from the onboard power outlet 72. The operator may
then pivot the door 232 (clockwise in FIG. 8) to the closed
position in which the extended portion 238 (and thus the notch 240)
clears the recess 242 and the covering portion 236 superposes above
(and completely covers) the recess 242.
In the disclosed embodiments, the door may be mounted for pivot
action about an axis that extends from the mounting surface. For
example, in FIGS. 5 and 6, the axis A may be perpendicular to the
mounting surface of the head 14'. In alternative embodiments, a
door may be mounted for pivot action about an axis that is parallel
to the mounting surface. With reference to the example onboard
power outlet 270 depicted in FIGS. 9 and 10, the electrical
contacts 273 of the onboard power outlet 270 may be flush with an
opening of the recess 272. The door 274 may be mounted (via a hinge
coupling, for example) on the cover for pivot action (in the
direction of arrow 280) between an opened position and a closed
position. As shown in FIG. 10, the door 274 may be located at an
intermediate position (between the opened position and the closed
position) so that he power cord 214 of the power tool enters into
the notch 276 and the door 274 retains the power plug 216 of the
power tool in the illustrated position. The operator may pivot the
door 274 (clockwise in FIG. 10) to the opened position to remove
the power plug 216 from the onboard power outlet 270. The operator
may then pivot the door 274 (counter clockwise in FIG. 10) to the
closed position in which the notch 276 enters into the recess 272.
The notch 276 is on a face of the door 274 that faces the power
outlet 273 when the door is in a closed position. In the closed
position, the door 274 may superpose above (and completely cover)
the recess 272. The outlet cover/door 274 pivots about an axis 275
that is parallel to a surface of the housing that surrounds the
power outlet 273.
In the disclosed embodiments, the door may be mounted on the vacuum
for pivot action. In alternative embodiments, the door may be
mounted on the vacuum for sliding action. With reference to the
example onboard power outlet 370 depicted in FIG. 11, the door 374
may include outwardly extending flanges 375 (only one of which is
shown that may be received in opposed guide grooves 325 (only one
of which is shown) provided in the recess 372. During the sliding
action (arrow 380) of the door 374 (between the opened and the
closed positions), the guide grooves 325 may limit and guide the
travel of the flanges 375 (and thus the door 374). The door may
include a notch 376 that extends in the travel direction of the
door 374. In this way, the door 374 may be slid to the closed
position in which the notch receives a power cord of a power tool.
It will be readily apparent that the recess 372 may include a
pocket (not shown) for receiving the door 374 when moved toward the
opened position.
In all of the disclosed embodiments, numerous and varied spring
elements that are well known in this art may be suitable
implemented to influence the door toward the closed position. In
the example embodiment depicted in FIGS. 5 and 6, by way of example
only, a spiral spring may be provided around the mounting pin
connecting together the door 206 and the head 14'. The radial inner
end of the spiral spring may be fixed to the mounting pin (or the
door 206) and the radial outer end of the spiral spring may be
fixed to the head 14'. An operator may pivot the door 206 toward
the opened position to load the spiral spring. When the operator
releases the door 206, the spiral spring may unload and influence
the door 206 toward the closed position.
In all of the disclosed embodiments, numerous and varied features
may be implemented to limit the movement of the door. For example,
in the embodiment depicted in FIGS. 5 and 6, stop features may
protrude from the surface of the head 14'. The stop features may be
located on the head 14' at respective positions that abut against
the door 206 in the opened and the closed positions.
* * * * *
References